This comprehensive and structured Process Equipment Failures training course aims at providing a clear understanding of the major degradation mechanisms that process equipment and systems will be subjected to during their operating life, how to identify them, their effect on the integrity of the equipment and what appropriate measures can be taken to prevent and control the resultant damage.

• Main aspects of mechanical testing of structures
• Knowledge of the main types of structural failure
• Aspects of structural integrity and mitigation techniques
• Safe control and best practice use of engineering equipment
• Inspection and non destructive methods

This BTS training course is intended for:

• Staff who use or supervise activities requiring the selection, design/fabrication or use of mechanical equipment or component parts
• Engineers who seek a basic understanding of the practical aspects of evaluation of structural integrity
• Operation, technical service and maintenance professionals from various processing plants involved in everyday operation, control, inspection and maintenance of equipment.
• Engineers and consultants dealing with planning of new production plants, retrofitting plants and introducing new technologies
• Technical professionals responsible for maintenance and repair of equipment
• Project and asset managers

Day One: Materials Testing and Failure

Competency Description: Participants need to gain a sound understanding of methods of mechanical testing of components and methods of failure examination in order to assess the structural integrity of components and equipment.

Key behaviours

• Comprehensive understanding of relevant methods of mechanical testing
• Gain insight into relevant types of failure mechanisms
• Understanding the factors and caused that influence structural failure
• Gain knowledge of the examination of failed components

Topics to be covered

• Course objectives and overview
• Materials Testing – Tensile, Impact, Hardness
• Types of Failures – Ductile/brittle fracture, Temperature Effects
• Analytical Tools – Visual examination of fracture surface, Fractography, Microscopy
• Industrial Failures – Examples of Failures and Causes

Day Two: Damage and Interpretation of Failure I

Competency Description: Participants need to understand relevant failure mechanisms of components, including fracture, fatigue and thermal (high temperature) influence, methods of failure examination and methods of determining the life of components and equipment subjected to several loading conditions.

Key behaviours

• Gain insight into relevant types of failure mechanisms including fracture, fatigue and high temperature applications
• Understanding the internal and external factors and caused that influence structural failure
• Gain knowledge of determining the life of components and equipment subjected to various loading conditions
• Reinforcement of knowledge of component life determination through worked examples

Topics to be covered

• Stress Concentrating
• Fracture Mechanics
• Fatigue Failure
• High temperature Creep
• Thermal Expansion and deflections
• Worked examples

Day Three: Damage and Interpretation of Failure II

Competency Description: Participants need to understand relevant failure mechanisms of components including corrosion and vibration damage, methods of failure examination and methods of determining the life of components and equipment subjected to several loading conditions.

Key behaviours

• Gain insight into relevant types of failure mechanisms including corrosion and vibration damage
• Understanding the internal and external factors and caused that influence structural failure
• Gain knowledge of determining the life of components and equipment subjected to various loading conditions
• Reinforcement of knowledge of component life determination through worked examples

Topics to be covered

• Wear, Galing and Fretting
• Principles and types of Corrosion damage and Mitigation
• Vibration of Equipment and Piping
• Vibration Condition Monitoring
• Technical Problem Solving and Decision-making Approaches

Day Four: Examples of Equipment Failure

Competency Description: Participants need to recognise the failure of specific components and equipment and have a sound understanding of methods of failure mitigation, maintenance and troubleshooting.

Key behaviours

• Appreciate relevant types of failure mechanisms of relevant components and equipment
• Gain knowledge of the examination of failed components and equipment
• Cain an understanding relevant maintenance and troubleshooting issues

Topics to be covered

• Pressure vessels and life extension
• Heat Exchangers
• Pumps and Compressors
• Mechanical Seals and “O” Rign Failures
• Bearing failure
• Pipes and Repair Techniques

Day Five: Inspection, Testing and Condition Assessment

Competency Description: Participants need to gain a sound understanding of methods of equipment inspection and relevant codes

Key behaviours

• Comprehensive understanding of relevant non-destructive testing methods
• Gain insight into estimating the remaining life of equipment and inspection intervals
• Gain knowledge of relevant inspection codes

Topics to be covered

• NDT Methods and Techniques
• Inspection of Process Equipment
• Examples of Remaining Life Calculations
• Relevant Inspection Codes, API 570, etc.
• Course Summary and Wrap-up

BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.